Tutorial: Stationary Quenching Analysis

Set up and run a stationary quenching analysis.

Open the Tutorial Model

Data files are available in the tutorial_models folder in the installation directory in Program Files\Altair\2025\InspireExtrude2025\tutorial_models\extrudemetal\tutorial-10\.
  1. Open the dumbbell_profile.x_t tutorial model file.
  2. Position the model as shown.
  3. Set the display units to Metric (mm kg MPa C s).

Orient the Model

Inspire Extrude assumes the extruded profile comes in a positive Z axis. These steps help to orient the profile in this axis automatically.

  1. On the ribbon, click the Quenching tab.
  2. Click the Orient icon.
  3. On the model, click the exit surface.

    The model is oriented such that the profile is in the +Z direction.

Create the Extruded Profile

The imported or created profile cross-section often does not have the desired length of the extruded profile, which is achieved in this step.

  1. From the Quenching ribbon, click the Profile icon.

  2. On the model, click the exit surface as shown.

  3. Enter 3000 mm for Profile Length.
The model should now have a profile identical to the below figure.

Create an Immersion Quenching Zone

  1. On the Quench icon, click the Create Quench System satellite.
  2. Click the Immersion icon.

  3. Change the quench box length L to 1000 mm.


    Note: Ensure the zone start is not 0 mm. This value provides the essential distance between the die opening and the quench box, where the leadout table is positioned.

Review Material Properties

  1. Click the Materials icon.

  2. Ensure that you are using the default material data for this analysis.
  3. Click OK to confirm.

Run Quenching Analysis

  1. Save the model.
  2. Click the Run Analysis icon.


  3. Enter and review the following parameters:
    • Process Data:
      • Project Name: dumbbell_profile
      • Profile Temp: 525.0 C
      • Puller Speed: 20.0 mm/sec
      • Simulation Time: 225.0 sec
      • Time Step Size: 1.0 sec
      • Select the Warpage Analysis check box
    • Mesh Size: Medium
  4. Click Run.


Review Results

  1. When the analysis is complete, double-click the name of the run to open the results.
  2. Select Analysis Explorer > Analysis Type > Warpage.
    In the Analysis Explorer, under Analysis Type, various subcases are available.
    The subcases are primarily grouped into two categories:
    • Sequential subcases, ranging from 1 to n [n is 46 in this setup]
    • Subcase 100000

    As previously mentioned, during the quenching simulation, you record the temperature distribution across the profile at regular intervals. The sequential subcases display the stress, strain, and deformation at specific time steps. For example, subcase 1 shows these parameters at the initial time step.

    The final subcase in the sequence (subcase 46 in this setup) illustrates the stress, strain, and deformation at the last time step.

    The number of subcases in the sequential group depends upon the time for which the simulation is carried out (225 seconds, in this setup) and the frequency at which you store the temperature (every 5 seconds).

    Typically, the temperature at which the profile exits the quench box is approximately 50–60° C, which is consistent with our case setups.

    The final step involves bringing the temperature down to room temperature, represented by subcase 100000. At this stage, the profile is at room temperature, and the stress remaining in the system is the residual stress.

Distortion Analysis

One of the main goals of warpage analysis is to determine the distortion, as the quenched profile reaches room temperature. To see this distortion, select subcase 100000.

To view overall distortion, select Result type > Displacement > Magnitude. This shows the overall deformation.

Figure 1. Overall Distortion of the Profile during Quenching


To view deformation in the Z direction, Select Result type > Displacement > Z. This shows the deformation in the Z direction (i.e., distortion in the direction of movement of the profile).

Figure 2. Distortion of Profile in the Z-Direction


Residual Stress

During the quenching process, high-temperature gradients lead to the formation of thermal stresses. These stresses can occur in different directions at any given point. Von Mises stress represents the equivalent stress (the second invariant of the stress tensor) at that point.

To visualize the von Mises stress distribution in the profile, select subcase 100000. In the Analysis Explorer, select Result Type > Von Mises Stress. This is the final subcase that gets the cumulative effect of the previous subcases and also the final cooling of the profile to the room temperature.

Figure 3. Von-Mises Stress Distribution in the Profile


Plastic Strain

As quenching progresses, the profile undergoes rapid cooling. This rapid cooling induces thermal stresses in the profile. If these thermal stresses exceed the material’s yield strength, the profile begins to deform plastically. Plastic deformation refers to permanent deformation, which remains even after the profile has returned to room temperature. Plastic strain is a scalar quantity that quantifies the extent of this permanent deformation.

To visualize the plastic strain, select subcase 100000. In the Analysis Explorer, select Result Type > Equivalent plastic strain.

Figure 4. Plastic Strain Distribution in the Profile